ASRS stands for Automated Storage and Retrieval System. It is sometimes written as AS/RS or AS-RS. These terms are used interchangeably and refer to the same category of warehouse automation technology.
All ASRS solutions share a common operating principle. They are enclosed systems designed to automatically store and retrieve goods with minimal manual intervention.
The process typically follows this flow:
Inventory enters the system through conveyors linked to receiving, repacking, or decanting stations.
Equipment such as robots, cranes, shuttles, or carousels moves items to optimal storage locations within high-density racking.
When an order is placed, the system automatically locates and retrieves the required items.
Completed orders leave the system through conveyors connected to picking stations, packing areas, or shipping zones.
The entire system is managed by software that connects with the Warehouse Management System (WMS) to keep everything running smoothly and accurately.
There is no one-size-fits-all ASRS solution. Depending on your inventory, throughput requirements, and operational needs, different types of ASRS offer unique advantages.
Unit-load systems are designed for large, heavy loads – typically pallets or large containers weighing over 450 kg. They use automated cranes or stacker cranes that run on rails in high-bay racking structures, reaching heights of 18 to 30 metres or more. Best for: High-density pallet storage, bulk handling, and long-term storage of large items.
Mini-load systems are similar to unit-load systems but are designed for lighter items stored in totes, bins, or cartons. They use smaller cranes that run in narrow aisles to retrieve items from high-density racking. Best for: Small-item fulfilment, store replenishment, and operations with fast-moving SKUs.
VLMs are enclosed towers with inventory stored vertically on trays on both sides of a central lift mechanism. Items are accessed via an operator window at the base as the lift retrieves the required tray. They dynamically adjust tray positions to maximise vertical space usage. Best for: Storing items of varying sizes, maximising vertical real estate, and applications requiring good security.
Carousel systems use rotating trays or bins that deliver items to a fixed workstation. Horizontal carousels rotate items around an oval track, while vertical carousels rotate items in a vertical loop. Both are compact and cost-effective for small parts. Best for: Compact, repetitive pick tasks, slow to medium moving SKUs, and MRO parts storage.
Shuttle systems use small, fast-moving battery-powered shuttles that run horizontally along rails at each storage level. A vertical lift is typically integrated to move items between levels, allowing access to multiple storage tiers. Shuttles transfer goods to conveyors or lifts, which then deliver them to picking or packing stations. Best for: High-SKU, mixed-velocity e-commerce flows and operations requiring incremental scalability.
The business case for ASRS is built on measurable, tangible benefits:
ASRS can achieve 80-90% space utilisation compared to 40-60% for traditional racking. Cube-based systems can offer up to 400% more storage in the same footprint.
Automated systems deliver consistent cycle times, with goods-to-person shuttle systems capable of delivering 500 to 700 items per hour.
Integrated with WMS, ASRS achieves accuracy rates significantly higher than manual operations.
Automation tackles labour shortages and reduces reliance on temporary staff.
Reducing manual handling and forklift traffic cuts workplace injuries.
ASRS does not take breaks, get sick, or need holidays.
Real-time data from the control system gives complete visibility over stock.
ASRS and traditional pallet racking represent two fundamentally different approaches to warehouse storage – one built around human access, the other engineered to eliminate it. Traditional racking leaves 40-60% of warehouse space unused because forklifts require operating clearance and wide aisles. ASRS eliminates these constraints, enabling warehouses to reach heights and densities that are simply impossible with manual systems.
ASRS solutions are deployed across a wide range of industries and applications:
ASRS supports high-throughput, multi-SKU fulfilment operations where speed and accuracy are critical.
ASRS can operate in cold storage environments and handle temperature-sensitive products.
ASRS works in chillers and freezers, with goods-to-person systems keeping operators at comfortable workstations.
ASRS supports just-in-time production by delivering components to assembly lines precisely when needed.
ASRS enables third-party logistics providers to handle multiple clients with diverse inventory profiles efficiently.
MotionTech has delivered ASRS solutions across the UK, including pallet shuttle systems integrated with vertical lifts, conveyors, and warehouse control software – fully tailored to each customer's existing WMS and operational requirements.
The cost of an ASRS varies widely depending on the type of system, scale, and complexity.
Note: these are starting prices. Fully integrated systems managing large SKU counts can exceed £2.5m+.
Despite the upfront investment, ASRS delivers substantial returns:
The return comes from multiple sources: labour savings (reduced headcount and temporary staff), space savings (higher density reducing property costs), accuracy improvements (fewer returns and write-offs), and throughput gains (faster order fulfilment).
Several factors influence the final cost: system size (larger systems have lower cost per cubic foot), environment (climate-controlled systems cost more), and stored product characteristics (heavy or oversized items require heavier-duty equipment).
MotionTech is the UK's end-to-end automation partner. With in-house manufacturing and a full portfolio of conveyors, ASRS, AMRs, and HELIX WCS software, we design, build, and support complete automated storage solutions tailored to your operation.
Unit 3, Charles Park, Cinder Hill Road, Bulwell, Nottingham NG6 8RE
0115 975 3300
Sales enquiries: sales@motiontech.co.uk
